1981 115 Evinrude Key Switch Will Not kill Engine

[pbailey]

Just picked up a good running 1981, 115 Envirude.<br />The person who sold it to me sent a set of controls with the engine. It did not have a key so, I purchased a new ignition switch. Wired the new switch in and started the engine for the first time and it fired right up. Ran it till it warmed up and was sure the thermostats were working. Turned the key off and it wouldn't shut off.<br /><br />The wiring diagram that came with switch was followed and I had all the correct wire colors to attach as indicated. There was a choice(I think) to wire the switch (swiched) or (non-switched) I wired it the same way the original one was. which was non-switched. So I thought this may be the problem so I changed it to switched and no change.<br /><br />I wired it as follows:<br />C: purple w/ white=primer<br />S: yellow w/red=start circuit<br />M: between S&B 2 leads black w/ yellow= stop curcuit.<br />B: red=b+<br />M: between B&A black=ground<br />A: purple=b+<br /><br />I'm assuming that swiched and non-switched means accessories switched or non-switched, since the wires used on the alternate lugs are both purple.<br /><br />I started checking the wiring harness out when I found the black with yellow (stop curcuit) had been cut at the control box wiring harness connector to engine harness connector. Connected this wire and tried to start. No go. Took that wire loose and started engine, connected the wire while running and it stopped. <br /><br />Checked dead man switch by connecting test light to yellow (start curcuit) and both sides of dead man. Dead man switch tested ok both sides of switch using this method. Didn't matter if the lanyard was attached or not. Refrerred to manual, but couldn't find anything to help me. Except that the wiring was correct.<br /><br />If anybody has any ideas, I would love to hear them.<br /><br />Thanks, <br />pbailey

 

[Joe Reeves]

Re: 1981 115 Evinrude Key Switch Will Not kill Engine

Pbailey..... What is it that you want a idea about? Perhaps I'm reading your post wrong.<br /><br />You've got a problem that the engine won't stop when you turn the key off. But then you say that if you connect the Black/Yellow wire that was cut, the engine will stop. The Black/Yellow wire is the kill wire leading to the powerpack(s).<br /><br />You then say that the kill switch (Lanyard) gives you a ohm reading on both terminals whether the lanyard is connected or not.<br /><br />That would indicate that the kill switch is faulty (shorted) and is the reason the Black/Yellow wire was cut (allowing the engine to run).<br /><br />If by pushing the kill switch button in manually, the ohm reading changes, indicating full on and full off, then the lanyard is faulty.<br /><br />If on the other hand, there is still no difference in the ohm reading, replace the kill switch.

 

[pbailey]

Re: 1981 115 Evinrude Key Switch Will Not kill Engine

Joe,<br /><br />Thanks for responding. After reading my post, I can see how I might have confused any readers.<br /><br />The engine cut off with the key in the ON postion when I connected the cut wire (black w/yellow) at the harness. From the manual I identified this as the stop circuit as it also runs through the lanyard switch. Operating the lanyard switch made no difference in operating conditions. This lead me to beleive that the stop switch was faulty.<br /><br />I used a test light, not an ohm meter to test power (or continuity) through the switch. this produced no changes in test regardless of switch position. The light stayed on with the switch in and out. <br /><br />I'm thinking that maybe the results of this test are meaningless because of where I connected the test light to. But I'm not sure. <br /><br />I will try to get an ohm meter and test for continuity through the switch. or put jumpers to eliminate the switch from the circuit. <br /><br />But I don't quite follow how that would cause the key switch to fail shuting down the engine when turning the key to the off position. I'm thinking that if the kill switch failed in the open position, it would only prevent me from starting the engine. If it failed closed, it would only prevent the kill switch from shuting down the engine when the lanyard was removed. I think. <br /><br />You know as I write this it came to me that it must be in the kill circut somewhere, because the cut kill circuit wire reconnected caused the engine not to start or to cut off when running when reconnected. <br /><br />DUH!!!!!!!!!!!!!!!!!!!!! <br /><br />I think maybe I'll eliminate the kill switch as the problem and move on from there. <br /><br />This is the first boat and engine I've ever rigged and I've been testing circuits and tracing wires all day. The boat is new to me as well and the wiring was so bad that I pulled it all out and started from scratch. Brain must have been overloaded.<br /><br />Thanks again Joe, for pointing out the obvious.<br /><br />pbailey

 

[Joe Reeves]

Re: 1981 115 Evinrude Key Switch Will Not kill Engine

A test light operates by conducting voltage. Connecting it to the black/yellow wire (leads to the kill circuit of the powerpack) can cause damage to the powerpack.<br /><br />You made the statement of "I'm thinking that if the kill switch failed in the open position, it would only prevent me from starting the engine. If it failed closed, it would only prevent the kill switch from shuting down the engine when the lanyard was removed."<br /><br />Therein lays your problem.... you are thinking backwards. The "Kill Switch" when closed kills the ignition, and when open allows the ignition to operate. (The kill switch should be open when the kill switch button is pushed in, closed when it is out).<br /><br />The ignition is self contained and is called a Magneto Capacitance Discharge system. AC voltage is generated by the flywheel magnets speeding around certain coils located in the stator. That AC voltage (300v) is applied to the powerpack capatitor which generates a higher voltage etc etc. This system operates as long as the powerpack is not grounded via the "Black/Yellow" wire circuit.

 

[pbailey]

Re: 1981 115 Evinrude Key Switch Will Not kill Engine

Jim,<br /><br />Thanks for the help. Took the kill switch out of the circuit and all is well.<br /><br />pbailey